Air flow methods and systems for a welder-generator

ABSTRACT

Configurations of internal components of a welder-generator are provided to improve efficiency of the cooling of the internal components. Configurations are provided in which a single fan, such as an engine fan, drives a single airflow path through the welder-generator. Configurations are provided in which a primary engine fan drives a first airflow path and a secondary generator fan drives a second airflow path through the welder-generator. Internal components are thermally aligned such that air circulates first through components with low critical operating temperatures and last through components with higher critical operating temperatures.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation Patent Application of U.S. patentapplication Ser. No. 12/500,032, entitled “Improved Air Flow Methods andSystems for a Welder-Generator”, filed Jul. 9, 2009, which is a U.S. Nonprovisional Patent Application of U.S. Provisional Patent ApplicationNo. 61/080,880, entitled “Improved Air Flow in a Welder-Generator”,filed Jul. 15, 2008, both of which are herein incorporated by referencein their entireties for all purposes.

BACKGROUND

The present disclosure relates generally to welding devices, and moreparticularly, to a welder-generator.

Welding is a process that has increasingly become ubiquitous in variousindustries and applications. While such processes may be automated incertain contexts, a large number of applications continue to exist formanual welding operations, which rely on the use of a welder-generatorto power the welding process. Welder-generators typically includeinternal components, such as electrical circuitry, a generator, anengine, and a muffler, which produce substantial amounts of heat duringoperation. Accordingly, an engine cooling fan at the rear of thewelder-generator and a supplemental fan in the middle of thewelder-generator are typically provided to cool the internal components.

The engine cooling fan is typically configured to circulate air from therear of the welder-generator through the engine to exclusively cool theengine during operation. The supplemental fan is typically located inthe center of the welder-generator, and is configured to circulate airfrom the front of the welder-generator through the electrical circuitryand the generator during operation. The airflow paths generated by thefans typically converge, flow over the engine and the muffler, and exitthe rear of the welder-generator. Such airflow systems allow theformation of a hot chamber in the center of the welder-generator andrequire high volumetric flows to prevent overheating of the internalcomponents. Furthermore, these systems require complex packaging becausemultiple baffles are needed to direct air along the desired pathways.

BRIEF DESCRIPTION

Configurations of internal components of a welder-generator are providedto improve efficiency of the cooling of the internal components. Thedisclosed embodiments include configurations in which a single fan, suchas an engine fan, drives a single airflow path through thewelder-generator. Additionally, embodiments are provided withconfigurations in which a primary engine fan drives a first airflow pathand a secondary generator fan drives a second airflow path through thewelder-generator. In disclosed embodiments, internal components arethermally aligned such that air circulates first through components withlow critical operating temperatures and last through components withhigher critical operating temperatures. Certain embodiments are providedthat require alterations to the connection mechanism between the engineand the generator. Accordingly, single bearing and dual bearingembodiments are provided for the connection of the engine and thegenerator.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of an exemplary welder-generatorillustrating airflow paths in accordance with aspects of the presentdisclosure;

FIG. 2 illustrates an exemplary airflow path through internal componentsof a welder-generator in accordance with aspects of the presentdisclosure;

FIG. 3 is a process flow diagram that representing operation of thewelder-generator of FIG. 2 in accordance with aspects of the presentdisclosure;

FIG. 4 illustrates an exemplary connection between an engine and agenerator that may be used in the exemplary welder-generator of FIG. 2in accordance with aspects of the present disclosure;

FIG. 5 illustrates an exemplary connection between an engine and agenerator that may be used in the exemplary welder-generator of FIG. 2in accordance with aspects of the present disclosure;

FIG. 6 illustrates exemplary airflow paths through internal componentsof a welder-generator in accordance with aspects of the presentdisclosure; and

FIG. 7 is a process flow diagram representing operation of thewelder-generator of FIG. 6 in accordance with aspects of the presentdisclosure.

DETAILED DESCRIPTION

As discussed in further detail below, various embodiments of awelder-generator are provided to efficiently cool internal components.The welder-generator is capable of allowing airflow both in and out ofrear vents, configured to facilitate thermal alignment of internalcomponents, capable of circulating airflow with a single fan, capable ofreducing the size of internal components as compared to traditionalsystems, and so forth. The disclosed embodiments include configurationsin which a single fan, such as an engine fan, drives a single airflowpath through the welder-generator. Additionally, embodiments areprovided with configurations in which a primary engine fan drives afirst airflow path and a secondary generator fan drives a second airflowpath through the welder-generator. Furthermore, internal components arethermally aligned such that air circulates first through components withlow critical operating temperatures and last through components withhigher critical operating temperatures. The foregoing features, amongothers, may have the effect of reducing the generation of noise outsidethe welder-generator, reducing or simplifying the parts (e.g., reducingthe number of baffles needed to direct air), reducing the power requiredto generate the necessary airflow volume, and so forth.

Embodiments are provided that include alterations to the connectionmechanism between the engine and the generator. Accordingly, singlebearing and dual bearing embodiments are provided for the connection ofthe engine and the generator. In some embodiments, the charging systemmay be relocated from the engine to the generator, thus possiblysimplifying the flywheel and reducing the weight of the engine assembly.For instance, removal of the charging system from the engine may allowthe flywheel to be reduced to a thin plate designed to exclusively holdthe ring gear. As discussed below, certain embodiments of thewelder-generator integrate some or all of the above described featuresin a single unit that may be coupled to additional system componentsduring use.

Turning now to the drawings, FIG. 1 illustrates an exemplary stickwelder-generator 10, which functions to power, control, and provideconsumables to a welding operation in accordance with aspects of thepresent disclosure. However, those skilled in the art would understandthat the present disclosure also relates to similar operations that maybe performed in which weldments are formed but the welding processdiffers (i.e., embodiments may be applicable to welder-generators usedfor MIG welding processes, TIG welding processes, and so forth).Accordingly, the system described herein is envisaged for use with allsuch operations where power is supplied to a location where welding iscarried out. In the illustrated embodiment, a front side 12 of thewelder-generator 10 contains a control panel 14, through which a usermay control the supply of materials, such as power, gas flow, and soforth, for a welding operation. Air, as represented by arrows 16, mayflow into the welder-generator 10 via vents 18 on the front side 12 ofthe welder-generator 10. Additionally, air, as represented by arrows 20,may flow into the welder-generator 10 via vents (not shown) on a backside 22 of the welder-generator 10. Expelled air, as represented byarrows 24, may also flow out of the welder-generator 10 via vents (notshown) on the back side 22 of the welder-generator. In some embodiments,incoming air, as represented by arrows 16 and 20, may be generallycooler than exiting air, as represented by arrows 24. That is, incomingair 16, 20 may cool internal components of the welder-generator 10, thusmaking the expelled air warmer. It should be noted that in someembodiments, the welder-generator 10 may be portable and may becommunicatively coupled to additional system components, such as a wallpower outlet, a battery, and so forth.

FIG. 2 is a cross sectional view of an exemplary welder-generator 26illustrating an exemplary layout of internal components in accordancewith one embodiment of the present disclosure. The welder-generator 26includes weld components 30, a generator 32, an engine 34, and a muffler36. In certain embodiments, weld components 30 may include rectifiers,reactors, stabilizers, electronic modules, PC boards, and so forth. Weldcomponents 30 are generally designed to be maintained at an operatingtemperature less than a designated level, such as less thanapproximately 100° C. In the illustrated embodiment, the generator 32includes a stator 35, which remains stationary and may function as amagnet or an electromagnet, and a rotor 37, which rotates via torquegenerated by the engine 34 and may function as a magnet or anelectromagnet. The generator 32 may be generally designed to bemaintained at an operating temperature less than a designated level,such as less than approximately 130° C. The engine 34 includes an engineblock 38, which provides a casing for internal components of the engine34. The engine 34 is generally designed to be maintained at an operatingtemperature less than a designated level, such as less thanapproximately 150° C. The engine 34 may include a radiator. The muffler36, which may include pipes and a can, is generally designed to bemaintained at an operating temperature less than a designated level,such as less than approximately 400° C.

The engine 34 also includes a fan 40 that is configured to cool theelectrical components 30, the generator 32, the engine 34 and themuffler 36 in the stated order. Accordingly, the fan 40 establishes anairflow path, as represented by arrows 42, through the internalcomponents of the welder-generator 26. That is, the single fan 40located in the engine 34 cools internal components such that componentswith low critical operating temperatures (e.g., weld components 30)experience the coolest air and components with high critical operatingtemperatures (e.g., the muffler 36) experience the hottest air. Thus,the present disclosure may offer distinct advantages over traditionalsystems because internal components are thermally aligned, wherethermally aligned may be defined as placing components with the highestcritical operating temperatures later in the air flow route and placingcomponents with the lowest critical operating temperatures earlier inthe air flow route. Thermal alignment maintains the desired temperaturedifference between the cooled component and the air stream performingthe cooling for all components in the system. The temperaturedifferential between air and component is directly proportional to theheat transfer achieved, and, thus, maintaining that differentialimproves the efficiency of a given air flow to provide cooling tocomponents which have varying critical temperatures. For instance, incertain embodiments, thermal alignment of internal components may allowfor a reduction in airflow quantities through the welder-generator 26while maintaining an effective cooling system. Additionally, becauseinternal components are thermally aligned, only the single fan 40located in the engine 34 is needed to generate the necessary airflowthrough the welder-generator 26, as compared to multiple fans intraditional systems. The foregoing features, among others, may have theeffect of reducing sound, reducing the size of the engine 34 andgenerator 32 assemblies, simplifying the parts required for the engine34 and the generator 32, reducing the amount of power necessary togenerate cooling airflow through the system, reducing the overall sizeof the unit, and so forth.

In the embodiment illustrated in FIG. 2, the generator 32 is located infront of the engine 34 relative to and close to a front 44 of thewelder-generator 26, and the engine 34 is located behind the generator32 close to a back 46 of the welder-generator 26, which is similar toconfigurations in traditional systems. However, the engine 34 is rotated180° as compared to traditional systems, thus allowing the fan 40 to belocated near a center 48 of the welder-generator 26 instead of towardthe back 46 of the welder-generator 26. The foregoing configuration maysimplify packaging of the welder-generator 26 since only one centerbaffle 50, as compared to multiple baffles in traditional systems, isused to isolate the engine 34 from other internal components.Additionally, the need for a fan in the generator 32 is eliminated sincethe fan 40 in the engine 34 is located in the middle 48 of thewelder-generator 26.

The disclosed configuration of the generator 32 and the engine 34 asillustrated in FIG. 2 establishes the airflow path 42 through thermallyaligned internal components in accordance with the flow chartillustrated in FIG. 3. The airflow path is initiated when the fan 40located in the engine 34 is powered on, as represented by block 54. Thecoolest air in the airflow path 42 is then drawn in the front 44 of thewelder-generator 26, as represented by block 56. This coolest air isfirst drawn through the weld components 30, which have a criticaloperating temperature of approximately 100° C., as represented by block58. The air is then drawn through the generator 32, which has a criticaloperating temperature of approximately 130° C., as represented by block60. Air exiting the generator 32 proceeds through the engine 34, whichhas a critical operating temperature of approximately 150° C., asrepresented by block 62. Air exiting the engine 34 then flows past oraround the muffler 36, which has a critical operating temperature ofapproximately 400° C., as represented by block 64. The hottest air thenexits the back of the welder-generator 26, as represented by block 66.In this way, a single airflow path 42 may be established to cool theweld components 30, the generator 32, the engine 34, and the muffler 36,which are thermally aligned.

The configuration of the engine 43 and the generator 32 described inFIG. 2 requires a new mode of connection between a back side 52 of thegenerator 32 and a fan side 54 of the engine 34. FIGS. 4 and 5illustrate two possible such modes of connection between the generator32 and the engine 34. In both configurations, a space is left betweenthe fan side 54 of the engine 34 and the back side 52 of the generator32 to allow for sufficient flow of air through and around the generator32 as necessary for cooling of the internal components. Specifically,FIGS. 4 and 5 illustrate attachment of the engine 34 to the generator 32in a 2-bearing design 68 including a pair of bearings 69 and a singlebearing design 70 including a single bearing 71, respectively.

FIG. 4 illustrates the 2-bearing design 68 in which a single connection72 exists, and a shaft 39 connects the engine 34 and the generator 32.In this embodiment, the shaft 39 rotates to transmit power from theengine 34 to the generator 32. The shaft 39 rigidly or flexibly connectsthe engine 34 and the generator 32 for proper alignment and resistsbending and axial loads during operation. The single shaft 39 connection72 allows the stationary engine block 38 and the stationary stator 35 toremain unconnected, which may have the effect of reducing mechanicalcomplexity.

FIG. 5 illustrates the single bearing design 70 in which two connectionsexist between the engine 34 and the generator 32. The shaft 39 stillconnects the rotating assemblies of the engine 34 and the generator 32with respect to FIG. 4. However, a connector 74 provides an additionalconnection point and may have the effect of reducing bending loads onthe shaft 39 during operation as compared to the 2-bearing design 68.The connector 74 may connect the stator 35 of the generator 32 with theengine block 38 of the engine 34. Accordingly, the single bearing design70 allows for both the stationary as well as the rotating parts of theengine 34 and the generator 32 to be connected. The foregoing featuresmay have the effect of providing alignment, rigidity, and coupling ofthe reactionary torque.

In certain embodiments, the configurations of the engine 34 and thegenerator 32 in the welder-generator 26 illustrated in FIGS. 2-4 mayallow for mechanical advantages over traditional designs. For instance,a flywheel 75, an internal component of the engine 34, may be simplifiedto a flex plate since the fan side 54 of the engine 34 faces the backside 52 of the generator 32, thereby allowing the rotor to provide theinertia necessary for system performance. Additionally, in someembodiments, a charging system may be removed from the engine 34, thusfurther simplifying the flywheel 75 since the flywheel 75 may only needto support ring gear. These features may have the effect of reducing theweight of the engine 34 and generator 32 assembly.

FIG. 6 is a cross sectional view of an exemplary welder-generator 76illustrating an exemplary layout of internal components in accordancewith another embodiment of the present disclosure. The welder-generator76 still includes weld components 30, the generator 32, the engine 34,and the muffler 36 with respect to FIG. 2. The engine 34 includes thefan 40, and the fan 40 is configured to cool the electrical components30, the engine 34 and the muffler 36 in the stated order. Accordingly,the fan 40 located in the engine 34 establishes an airflow path, asrepresented by arrows 78, through select internal components of thewelder-generator 76. That is, the fan 40 located in the engine 34 coolsselect internal components such that components with low criticaloperating temperatures (e.g., weld components 30) experience the coolestair and components with high critical operating temperatures (e.g., theengine 34 and the muffler 36) experience the hottest air. In thisembodiment, an additional fan 80 located in the generator 32 isconfigured to exclusively cool the generator 32. Accordingly, the fan 80located in the generator 32 establishes an airflow path, as representedby arrows 82, through the generator 32. The airflow path 82 generated bythe fan 80 located in the generator 32 converges with the airflow path78 generated by the fan 40 located in the engine 34 and exits out a back84 of the welder-generator 76. The additional fan 80 located in thegenerator 32 may be smaller than traditional generator fans because thefan 80 would only need to cool a single component.

In the embodiment illustrated in FIG. 6, the engine 34 is located infront of the generator 32 close to a front 86 of the welder-generator76, and the generator 32 is located behind the engine 34 close to theback 84 of the welder-generator 76. In this embodiment, the engine 34and the generator 32 remain connected but are rotated together 180° ascompared to traditional systems, thus allowing the engine 34 and thegenerator 32 to be mechanically connected as in previous systems. Thatis, a new mode of connection between the engine 34 and the generator 32may not be used in this embodiment. In this embodiment, the generator 32may fit underneath the muffler 36, thereby allowing for possibleshortening of the length of the welder-generator 76 if desired.

The disclosed configuration of the generator 32 and the engine 34 asillustrated in FIG. 6 establishes the airflow paths 78 and 82 throughthermally aligned internal components in accordance with the flow chartillustrated in FIG. 7. The airflow path 78 is initiated when the fan 40located in the engine 34 is powered on, as represented by block 88. Thecoolest air in the airflow path 78 is then drawn in the front 86 of thewelder-generator 76, as represented by block 90. This coolest air isfirst drawn through the weld components 30, which have a criticaloperating temperature of approximately 100° C., as represented by block92. Air exiting the weld components 30 proceeds through the engine 34,which has a critical operating temperature of approximately 150° C., asrepresented by block 94. The parallel airflow path 82 is initiated whenthe fan 80 is powered on, as represented by block 96. The fan 80 drawsair into the back 84 of the welder-generator 76, as represented by block98, and through the generator 32, as represented by block 100. Theairflow paths 78 and 82 converge and flow around or past the muffler 36,which has a critical operating temperature of approximately 400° C., orthrough the muffler 36, as represented by block 102. Air exiting themuffler 36 then flows out the back 84 of the welder-generator, asrepresented by block 104. In this way, airflow paths 78 and 82 may beestablished to cool the weld components 30, the generator 32, the engine34, and the muffler 36.

While only certain features of the present disclosure have beenillustrated and described herein, many modifications and changes willoccur to those skilled in the art. It is, therefore, to be understoodthat the appended claims are intended to cover all such modificationsand changes as fall within the true spirit of the present disclosure.

1. A welder-generator system comprising: an engine comprising a fanintegral with the engine; a generator; a muffler; and weld components;wherein the fan is configured to establish an airflow path through whichairflow flows to the weld components, to the generator, to the engine,and to the muffler in the recited order.
 2. The welder-generator systemof claim 1, comprising a baffle configured to separate suction andpressure sides of the fan.
 3. The welder-generator system of claim 1,wherein the engine, the generator, the muffler, and the weld componentsare thermally aligned.
 4. The welder-generator system of claim 1,wherein the fan and the airflow path are configured to generate airflowthat cools internal components of the welder-generator system in anorder such that components with the lowest critical operatingtemperatures are in the coolest air and components with the highestcritical operating temperatures are in the hottest air.
 5. Thewelder-generator system of claim 1, wherein the weld components compriserectifiers, reactors, stabilizers, electronic modules, PC boards, or acombination thereof.
 6. The welder-generator system of claim 1,comprising an enclosure, wherein the engine, the generator, the muffler,and the weld components are disposed within the enclosure.
 7. Awelder-generator system comprising: an engine comprising a first fanintegral with the engine; a generator comprising a second fan integralwith the generator; a muffler; and weld components; wherein the firstfan is configured to establish a first airflow path through which afirst airflow flows to the weld components, to the engine, and to themuffler in the recited order; and wherein the second fan is configuredto establish a second airflow path through which a second airflow flowsto the generator and to the muffler in the recited order.
 8. Thewelder-generator system of claim 7, comprising a baffle configured toseparate suction and pressure sides of the first fan.
 9. Thewelder-generator system of claim 7, wherein the muffler, the engine, andthe weld components are thermally aligned.
 10. The welder-generatorsystem of claim 7, wherein the first airflow path and the second airflowpath are configured to generate airflow that cools internal componentsof the welder-generator system in an order such that components with thelowest critical operating temperatures are in the coolest air andcomponents with the highest critical operating temperatures are in thehottest air.
 11. The welder-generator system of claim 7, wherein thefirst airflow path and the second airflow path converge before exitingthe welder-generator system.
 12. The welder-generator system of claim 7,wherein the weld components comprise rectifiers, reactors, stabilizers,electronic modules, PC boards, or a combination thereof.
 13. Thewelder-generator system of claim 7, comprising an enclosure, wherein theengine, the generator, the muffler, and the weld components are disposedwithin the enclosure.
 14. A method comprising: establishing a firstairflow path from a first fan of a welder-generator through which afirst airflow flows to weld components of the welder-generator, to anengine of the welder-generator, and to a muffler of the welder-generatorin the recited order; and establishing a second airflow path from asecond fan of the welder-generator through which a second airflow flowsto a generator of the welder-generator and to the muffler in the recitedorder.
 15. The method of claim 14, wherein suction and pressure sides ofthe first fan are separated by a baffle.
 16. The method of claim 14,wherein the weld components, the engine, and the muffler are thermallyaligned.
 17. The method of claim 14, wherein the first airflow path andthe second airflow path are configured to generate airflow that coolsinternal components in an order such that components with the lowestcritical operating temperatures are in the coolest air and componentswith the highest critical operating temperatures are in the hottest air.18. The method of claim 14, comprising converging the first airflow pathand the second airflow path prior to exiting the welder-generator. 19.The method of claim 14, wherein the weld components comprise rectifiers,reactors, stabilizers, electronic modules, PC boards, or a combinationthereof.
 20. The method of claim 14, wherein the engine, the generator,the weld components, and the muffler are disposed within a commonenclosure of the welder-generator.